Kitchen remodel with structural work

[Rob Z]

We  finished this job a while ago, but I finally just got back to take a full set of pictures.  

This circa 1953 house is solidly built, and for the most part it has held up well over the years.  Like many houses of that era, the rooms are somewhat small and cut-up.  This entire project started when my client mentioned to me that she would be hosting her family for Thanksgiving, and she wished that everyone could sit together and socialize  in a larger, more open space.   We had already done extensive work in the house (four bathrooms, media room, the basement, an exercise room, windows, doors, etc), and my client said "Well, it's about time to do the kitchen-when can you start?"   I suggested taking out the wall between the dining room and the kitchen, and she said to do what was needed to make it happen.

A structural  engineer detailed all the specs needed for the flitch beam needed to support the roof load which had been carried by the wall between the kitchen and dining room.  He also provided the detail needed to strengthen the joists under the kitchen. These joists had been hacked up over the years for plumbing and gas lines.

My kitchen designer developed the cabinetry layout.  My lighting designer planned the lighting for us.  And my good friend and cabinet maker Joe  built the cabinetry for us.

I've organized the photos in a bit of a before and after arrangement.  I have also included some pictures of the structural work, which was really challenging and fun to do.

The client and her family were thrilled with the results.   We had a great time doing the work

 

[Rob Z]

The wall in the attic (left side of the picture - which is carrying the roof load ) is the one that was cut out and replaced with the flitch beam.  The new platform was added to hold a heat pump which was installed as part of this project,

 

[Rob Z]

more pictures...

 

[Ken Nagrod]

Nice job, Rob.  I noticed a lot of light wells in the house.  Were they put in by you too?

The only thing that really stands out to me, that I don't like in the kitchen is the under cabinet lighting.  You can too easily see the reflections in the tile backsplash and it reminds me of runway lighting.

Great improvement to the look and value of the house!

 

[Ken Nagrod]

I like your tile work too.

 

[Rob Z]

Hi Ken,  We installed some of the skylights in the house, and some of them were installed by a subcontractor during another block of work at the house.  I considered removing the one in the kitchen and the dining room, but once everything was finished it seemed OK to leave them in place.  There is so much light that comes through the new bay window and the two skylights that often during the day no electric lights are needed.

I hear you about the undercabinet lights.  I think they are rarely turned on to max luminosity, and they don't show up as much as they do in these photos.

 

[Rob Z]

Oh....the skylights are the brand  "SolaTube" .  Very nice product.

 

[GhostFist]

Stunning work Rob! What a transformation! Love it

 

[Jeff Zanin]

Very nice work, what a change from before to after.

I am particularly interested in the part about reinforcing the joists with steel - was this to take flex out of the floor and/or support the weight of new flooring?

I have a similar situation and the usual suggestion is to sister the existing 2x10s, but there is a lot of ducting and plumbing that would make that awkward.

From your photo it looks like you bolted some sort of U channel to the joists, is that correct?  Is the steel supported at the ends of the joists or just a stiffener?

Jeff

 

[Jonhilgen]

Rob, that is awesome.  Would love to be involved in a project like that from start to finish, since I'm so pigeon-holed into cabinetry and cabinet installs.

Great looking job and congrats on the finished results as well as the repeat business from your clients.

Jon

 

[Rob Z]

Thanks for the positive comments everyone.

Jeff, If I recall correctly, that steel channel was designated as "C5X9", which means it's C-shaped in cross section, 5" tall, 9 pounds per lineal foot. 

We installed it to stiffen the floor joists, many of which were hacked up a bit from earlier work by plumbers and gas fitters.  We didn't opt for the somewhat less expensive option of sistering wood joists because of the ductwork.  Much of the ductwork had to come out to be replaced anyway (leaks and corrosion had ruined some sections of ductwork), so I worked out with my duct man how he would replace runs of ducts and the fittings which made the turns in the floor below and through the spaces around the steel I-beam and the block foundation walls.

The steel C-channel was run as far as possible over the bearing points of the joists. In some locations, we couldn't get the steel completely over the bearing below because of the space available to maneuver the steel into position.    The steel channel is  run down the centerline of the joist.  The engineer's calculated deflection on these joists was fantastic...something like L/2000 !

 

[Rob Z]

Hi Jon,  The guy that is setting the parallam post in the picture above is my buddy Joe.  He and I have done jobs together for the past 15+ years.  A few years ago he closed his shop here and relocated to Charleston SC.  He loves it there. 

I measured everything and sent the measurements to him in SC.  He made the cabinets in Charleston and trailered them up here and did the installation with us.  . 

 

[tiralie]

Great looking job Rob!
I particularly liked how you detailed the structural elements. Quite the challenge.
Sounds like you have a great client.
Tim